IPM IP01 Series User manual

IP-01
1:1 RATIO TRANSFER PUMP
OPERATING MANUAL
IPM, INC.
Manufactured by International Pump Manufacturing, Inc.
Covers models: IP01, IP01S, IP01-SST and IP01S-SST. Manual Number: MIP11192008

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IP-01
1:1 RATIO TRANSFER PUMPS
OPERATIONS MANUAL
WITH PARTS IDENTIFICATION
This manual contains IMPORTANT WARNINGS and INSTRUCTIONS. Read and retain for future reference.
International Pump Mfg, INC.
3107 142nd Avenue E Suite 106,
Sumner, WA 98390
U.S.A.
TEL: [phone]
FAX: [phone]
Website : www.ipmpumps.com
For Technical Service Call Your Local Distributor
Copyright 2004 International Pump Mfg, Inc.
Printed November 2008
WARNING: The equipment described herein must only be operated or
serviced by properly trained individuals, thoroughly familiar with the
operating instructions and limitations of the equipment.
Notice: All statements, information and data given herein are believed to be accurate and reliable but are presented without guarantee, warranty or
responsibility of any kind expressed or implied. Statements or suggestions concerning possible use of IPM equipment are made without representation
or warranty that any such use is free of patent infringement, and are not recommendations to infringe any patent. The user should not assume that all
safety measures are indicated or that other measures may not be required.

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TABLE OF CONTENTS
1.0 SAFETY WARNINGS 4
2.0 INSTALLATION 8
3.0 OPERATIONS
3.1 Working principle of transfer pump (fluid section) 10
3.2 Start-up and adjustment of the pump 11
3.3 Shut-down procedure 11
3.4 Daily maintenance check 12
3.5 Disassembly procedure 12
3.6 Assembly procedure 16
4.0 PARTS DIAGRAMS AND PART LISTS FOR ALL PUMPS
4.1 Parts drawing and parts list for Air Motor Section (All pumps) 17
4.2 Parts drawing and parts list for IP01 (Fluid section) 19
4.3 Parts drawing and parts list for IP01S (Fluid section) 21
4.4 Parts drawing and parts list for IP01SST (Fluid section) 23
4.5 Parts drawing and parts list for IP01S-SST (Fluid section) 25
5.0 REPAIR KITS 27
6.0 TROUBLE SHOOTING 28
7.0 TECHNICAL SPECIFICATIONS 29
8.0 WARRANTY AND DISCLAIMER 32

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1.0 SAFETY WARNINGS
Please read and observe all warnings contained in this operations manual before any attempt to
operate the equipment.
Misuse of Equipment
Misuse of the Equipment can cause serious injury. Use the equipment only for its intended purpose.
Care should be taken to prevent over pressurization of the pump or accessories connected to it. Use
only proper parts in good condition. Use the pump only with compatible fluids. Improper use or
misuse of this equipment could result in fluid being splashed on the skin or in the eyes, serious bodily
injury, property damage, fire or explosion.
Make daily check on the equipment and repair damaged or worn parts immediately.
Do not alter this equipment, doing so could cause it to function incorrectly and could cause serious
injury.
Material & Fluid compatibility
Always ensure the chemical compatibility of the fluids and solvents with the wetted parts in the pump
and any components. Check the fluid manufacturer’s data sheets and specifications before using the
fluids or solvents in this pump.
Pressurized Hoses
Because the hoses are pressurized, they present a danger should the fluid escape at high pressure.
This escaping fluid pressure can spray out and cause serious bodily injury or property damage.
Ensure that the hoses do not leak or rupture due to wear, misuse or damage.
The hoses should be handled properly - do not pull on the hoses to move the equipment around. Use
the hoses only for fluids in which they are compatible both for the inner liner of the hose and the outer
covering. Use care not to exceed the temperature rating of the hose.
Before each use, ensure that the fluid couplings are tight and that the entire length of hose is not
worn or damaged. Check the entire hose for leaks, bulging cover, damage, abrasion or cuts. These
conditions may cause the hose to fail that could result in splashing of pressurized fluid on the skin, or
in the eyes and cause serious bodily injury or property damage.
Pressure Specification
The maximum working fluid pressure of this equipment is 180 psi (12.5bar) at the maximum incoming
air pressure of 180 psi (12.5bar). Ensure all equipment and accessories used with this pump are
rated to withstand the maximum working pressure of this pump. Never exceed the maximum working
pressure of the pump or any device attached to the pump.
Procedure for Pressure Relief
In order to avoid the risk of serious bodily injury such as splashing fluid on the skin or in the eyes, or
risk of injury from moving parts, the following procedure should be used. This procedure should be
used when shutting down the pump, when servicing or repairing the pump or any part of the system,
when replacing or cleaning components, or when pumping of fluid is stopped.
1. Close the air valve to the pump.

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2. Use the air bleed down valve (see installation instructions) to relieve the air pressure in the
system.
3. Relieve the fluid pressure by holding a grounded metal pail in contact with the metal part of the
fluid dispense valve and slowly opening the valve.
4. With a container ready to catch the fluid open the drain valve (see installation instructions).
5. It is a good practice to leave the drain valve open until it is time to dispense fluid again.
If you are unsure that the fluid pressure has been relieved (due to a blockage in a component or a
hose) be careful to relieve the pressure by slowly loosening the hose end coupling to allow the fluid
pressure to escape slowly. After the pressure has been relieved, the fitting can be removed
completely and any blockages removed.
Flush the Pump before Using It
1. The pump is tested with lightweight DOP oil, which is left in to protect the pump parts. If the
fluid you are pumping may contaminated by oil, Flush out the oil with a compatible solvent
before using the pump. Follow the Flushing Instruction below:
.
2. If you are pumping fluid that dries, harden or sets up, flush the system with a compatible
solvent as often as necessary to prevent build-up of dried fluid in the pump or hoses.
3. If the pump is being used to supply a circulating system, allow the solvent to circulate through
the entire system for at least 30 minutes every 48hrs, or more often if the necessary to prevent
settling.
4. Always fill the wet -cup with 1/2 full of throat seal liquid (TSL) or compatible solvent to keep the
fluid from drying on the displacement rod and damaging pump throat packing.
5. Lubricate the throat packing frequently, when you are pumping a non-lubricating fluid, or are
shutting down for more than a few days.
Shut down & care of the Pump
For Overnight shut down, follow the Pressure Relief Procedure.
Always stop the pump at bottom of the stroke to prevent the fluid from drying on the exposed
displacement rod and damaging the throat packing.
Warning
To reduce the risk of static sparking or splashing fluid in the eyes or on the skin, follow
the Pressure Relief Procedure before Flushing.
For your safety, read the Fire or Explosion Hazard before flushing and follow all the
recommendations.

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Hazards from Fire or Explosion
Hazards exist when sparks can ignite vapors or fumes from flammable or combustible materials or
other hazardous conditions (explosive dusts, etc.). These sparks can be created from plugging in or
unplugging an electrical supply cord. Sparks can also be created from the static electricity generated
by the flow of fluid through the pump and hose.
Every part of the equipment must be properly grounded to prevent static electricity from generating a
spark and causing the pump or system to become hazardous. These sparks can cause a fire,
explosion, and serious bodily injury and property damage. Ensure that the pump and all components
and accessories are properly grounded and that electrical supply cords are not plugged in or
unplugged when these hazards exist.
Should any evidence of static electricity (sparks or small shocks while in contact with the equipment)
exists, discontinue the operation immediately. Investigate the source of the static electricity and
correct the grounding problem. Do not use the system until the grounding problem is repaired.
Grounding Procedures
Grounding of the pump and all other dispensing equipment is necessary to minimize the possibility of
sparks due to static electricity. Grounding must be in compliance with local electrical codes. Check
with the local authorities for requirements in your area and with the type of equipment being used.
Ensure that all the following equipment is grounded:
1. Air Compressor: Follow the grounding procedures as recommended
by the manufacturer.
2. Air Hoses: Use grounded air hoses.
3. Fluid Container used to
supply the system: Grounding must be done according to local codes.
4. Pump: Follow the procedures included referring to Figure 1.
5. Fluid Hoses: Use grounded fluid hoses.
6. Dispensing Valve: The valve must be metal to conduct through the fluid hose
to the pump which must be properly grounded.
7. Dispensing Point: Grounding must be done according to local codes.
8. Solvent Containers: Grounding must be done according to local codes. Use metal
conductive pails that are properly grounded.
9. Grounding while Maintain conductivity by firmly holding the metal part of the
dispensing, cleaning, dispensing valve to the side of a grounded metal container
or relieving pressure:

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FIGURE 1
Grounding the Pump:
Follow these procedures for grounding the pump. Loosen the lock screw (W) to allow insertion of one
end of a 12 gauge minimum size wire into the hole in the side of the lug (Z). Insert the wire (Y) and
tighten the lock screw securely. The other end of the ground wire must be secured to a true earth
ground.
Hose Grounding:
It is very important that the hoses used for both air and the fluid be a grounding type and that this
ground continuity is maintained. Regular checks of the hose ground resistance (with a resistance
meter using a suitable range) and a comparison to the Manufacturer’s Specification will ensure the
ground is within specifications. If it is not within specified limits it should be replaced immediately.
Solvent Cleaning:
While cleaning the system with solvent, hold the metal part of the dispensing valve in contact with a
grounded metal pail to minimize the possibility of splashing fluid on the skin or in the eyes or static
sparks. Use low fluid pressure for additional safety.
Hazards From Moving Parts:
Use the Pressure Relief Procedure to prevent the pump from starting unintentionally when not
desired. Take care that moving parts present a pinching hazard to fingers or other body parts. Stay
clear of these moving parts when starting or operating the pump.
Safety Standards:
Safety standards have been established by the United States Government under the Occupational
Safety and Health Act. These standards should be consulted as they apply to the hazards and type of
equipment being used.

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2.0 INSTALLATION
FIGURE 2
Figure 2 depicts a typical installation provided as a guide for your reference. Select and install
optional accessories required. Feel free to call your IPM representative or the IPM Technical
Department for assistance.
½”

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2.1 Mounting Configuration
Install the necessary accessories in sequence using Figure 2 as a guide. An Air Control Valve (K) for
Controlling air flow is required with the equipment. To minimize the risk of serious bodily injury such
as splashing fluid on the skin or in the eyes or risk of injury from moving parts, install the following
accessories in your system.
1. Bleed-off master air valve (D)
This valve will relieve the air trapped within the system after the pump is stopped. Air that is
trapped between this valve and the pump can cause the pump to reciprocate unintentionally,
which may cause harm to the operator.
2. Fluid Drain Valve (G)
The fluid drain valve (use a metal valve for grounding purposes) is installed to relieve fluid
pressure in the pump, hose or the dispensing valve when the pump is stopped. The relief of
pressure by the dispensing valve, which at times is inadequate if there is a clog or restricted
passage in the hose or the dispensing valve, can be achieved by using this fluid drain valve
(G).
Connect an air lubricator (C). The lubricator provides proper lubrication to the air motor. (see daily
maintenance check). Next, install a bleed-off master air valve (D). This valve is required in your
system to relieve trapped air (as explained above).
Air Filter (E) helps to remove dirt and foreign particles from the supply air, water moisture also will be
trapped within this filter. Be sure to release the trapped water daily as a good housekeeping practice
(Also see daily maintenance check). Connect a grounded air supply hose for the supply of air.
For the fluid section, connect one fluid drain valve (G) directly after the outlet of the pump. Be sure to
connect it pointing downwards for safety. Connect a grounded fluid hose (M) to the fluid outlet 3/4”
NPT(female).
Grounding of the pump and accessories are to be ensured before operation. Observe all
OSHA regulations and other safety regulations.

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3.0 OPERATIONS

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3.2 Start up and Adjustment of the Pump
Ensure that installation is fully completed before proceeding to start up operations.
1. Ensure that the air control valve (K) is closed. Open the bleed-type master air valve (D).
Connect the quick disconnect coupler to the male fitting.
2. Into a grounded metal container, open the dispensing valve (G) slowly. Ensure metal-to-metal
contact between the container and the valve.
3. Adjust the pump air control valve (K) slowly for pressure just enough to start running the pump.
This is to prime all air within the system. After all the air has been expelled from the lines, close
the dispensing valve. During the priming of the pump, the pump runs when the dispensing
valve is opened, and stop when the valve is closed.
4. Turn the air regulator slowly until sufficient flow from the dispensing valve is achieved.
Remember to run the pump always at the lowest possible speed necessary to achieve what is
desired. Never exceed the maximum working pressure of any component in the system.
5. The pump should not be left to run dry of the fluid being worked upon. When running empty,
the speed will become very quickly and probably damaging itself. During operation, should the
pump be found to run too fast, stop it immediately and check the fluid supply. Is the fluid level
in the drum too low or empty? If air has gone into the system, do a priming procedure. Ensure
that all air has been expelled from the lines before operation again. Flush the pump or leave it
filled with a compatible solvent when not in use.
6. Always follow the Pressure Relief Procedure should the pump be put away for any period of
time or during system shut off at the end of the day.
3.3 Shut Down Procedure:
1. Relieve the air pressure with the air regulator.
2. Open the air needle valve.
3. Bleed off residual pressure in the system with the Bleed-off master air valve.
4. Open the drain valve to relieve fluid pressure in the system. Use a container to collect the fluid
drained off. Be especially careful as the fluid may still be under pressure. Hold the metal
fluid drain valve against the side of the grounded container while relieving the pressure.
Note: For long periods of shut-down, flush the pump thoroughly with an appropriate
cleaning fluid.

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3.4 Daily Maintenance Check:
1. Ensure sufficient lubricant in the air lubricator.
2. Keep the packing cup ½filled with a suitable fluid (it will keep the piston rod clean and
lubricate the packing).
3. Drain the moisture trapped in the air pressure cylinder.
Clean and flush the pump thoroughly with care and appropriate cleaning fluid to
obtain the maximum service life of the equipment.
3.5 Disassembly Procedure: (See 4.1 and 4.2 diagrams for corresponding reference numbers)
1. All inlet and outlet hoses to be removed and the pump moved to a suitable work area.
2. Clamp on the housing (8) with the outlet hole against one of the jaws of the vice.
Alternatively, a pipe clamp may be utilized instead of a vice. When clamping the housing-
it becomes possible to remove either the air cylinder or the lower tube and/or foot valve.

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3. Remove the foot valve (27), while holding the cylinder (14) with a strap wrench as shown.
4. Use snap ring pliers to remove (24) and (25). Remove ball (26) and examine for debris and/or
damage. Replace as necessary. Replace Teflon o-ring (9). Re-assemble for valve (27) with
ball (26), snap rings (24) and (25). Please see the note on foot valves at the end of this
section.
5. With a strap wrench close to housing (8), unscrew cylinder (14). While removing cylinder, take
care NOT to bend the piston rod (18). Examine cylinder (14) for scratches in the cylinder wall
by looking through the cylinder at an angle to a light source.
6. At this point you can remove the connecting rod (18) from either the displacement rod (16) or
the internal foot valve (19-27) from the connecting rod (18). Typically, you will be taking apart
the internal foot valve assembly to inspect and clean.

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7. Please note that you need to loosen the jam nuts (17), and then retighten upon assembly.
8. Clamp piston valve housing (19) in vice and unscrew piston pump (23). Remove piston cup
(22) and examine for damage; replace if necessary. Check piston valve (20) within the
housing (19) for build up and debris.
9. Re-assemble the piston pump (23) to the piston valve housing (19) with the piston valve (20),
washer (21) and piston cup (22) in place. Shown in the picture below are the complete set of
components for the upper check valve.
10. Re-assemble the jam nut (17) onto the connecting rod (18). Install the piston valve housing
assembly (19) onto the connecting rod (18). Adjust the housing (19) so that the distance
between the connecting rod (18) and the piston valve (20) has a gap of 0.060” to 0.080”. Use
a feeler gauge for accuracy. This gap is extremely important because too much gap will
not allow the fluid to flow correctly, too little (or no gap at all) will constrict the flow.
11.From the fluid section drawing, remove the three cap nuts (1) from the tie rods (4). Slide
complete air piston assembly (25) out through the outlet housing (8). Please note that (25) is
shown in the Air Motor section 5.1.

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12.From the Air Motor section 5.1, remove the cotter pin (16) and pull out the pin (17). Unscrew
the displacement rod (16*) from the piston shaft (15). *The displacement rod is shown in the
fluid section 5.2.
13.From section 5.2, remove the packing nut (2) from the outlet housing (8), and remove
packing’s (3, 5 and 6) from the outlet housing. Examine all packing’s for damage and replace
as necessary. Examine the displacement rod (16) for damage- principally scratches along its
length. Replace if necessary. Re-assemble the packing parts (3, 5 and 6) and snug up the
packing nut (2). Take care not to over-tighten the packing nut. Make sure and lubricate the
packing’s before installing them.
14.Clamp the Air Motor assembly in to a vice, holding
by base (19). Using a strap wrench near the base
as shown, remove the air cylinder (4). Examine the
spring (3) in the air motor cap (1) to ensure that it is
not damaged or loose. Slide the air piston
assembly (25) with the piston shaft (15) out through
the base (19). Examine the V-block packing (18) for
damage and replace. Examine the gasket (2) in the
air motor cap, and replace if needed. This gasket
seals the cylinder cap to the air cylinder. Look at
section 5.1 for a complete illustration and the part
reference numbers.
Outlet Housing
Tie rod
Cotter pin
Locking nut
Piston shaft

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15.From fluid section, unscrew displacement rod (16) from the piston shaft (15 from section 5.1).
Examine for damage due to debris build-up. Re-assemble the muffler (24), with the point of
the cone up- inside the piston shaft and the displacement rod (16) to the piston shaft.
16.From section 5.1, remove the air motor piston assembly (25) from the piston shaft (15).
Remove the cap screws (1). Examine the o-rings (8 and 9) and replace where necessary.
3.6 Assembly Procedure:
1. Align air piston assembly with (5, 6, 7, 8, 9, 10, 11 and 12). The air exhaust valve plate (5) and
the screws (12) require the use of Loctite-222 on the threads to ensure they do not vibrate loose.
Tighten the screws to 10-14 inch pounds.
2. Assemble the complete piston assembly (use Loctite-222), with washer (13) onto the piston
shaft (15). Hand-tighten only.
3. Slide complete piston and shaft assembly into the air motor base (19). Make sure that the two
gaskets (2) are in the correct position. Clamp the air motor base in to a vice and use a strap
wrench to assemble the air cylinder (4) and the air cylinder cap (1) to the air motor base. Hand
tighten the air cylinder cap. Connect piston shaft (15) to displacement rod (16*) with Pin (17)
and cotter pin (16). Install tie rods (4*) in outlet housing (8*). Insert piston shaft through the
packing’s and install the lock nuts (1) with Loctite-242 and torque to 8 inch pounds. (*Appears
in diagram 5.2)
4. Assemble suction piston assembly to displacement rod (16) by screwing until the threads
bottom-out with the jam nut (17). Then tighten the jam nut.
5. Replace o-ring (9) in outlet housing (8). Use Loctite on threads for cylinder (14) and screw into
outlet housing. Hand-tighten cylinder in place.
6. Use Loctite-242 on the threads exposed on the cylinder (14) and tighten foot valve (27) in
place.
A NOTE ON FOOT VALVES: All foot valves have been converted to a larger flow style. This is
to reduce out-gassing and suction pressure. While the foot valves are readily interchangeable with
the older style, the internal components are not- so take care when ordering replacement parts.

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4.0 Air Motor parts diagram and part list for all pumps
4.1 Parts Drawing for AIR MOTOR Section (all pumps)
Note: Part number 12 (threads) and part
number 5 require the use of Loctite-222 to
help ensure they do not come undone.

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4.1 Parts list for AIR MOTOR Section (all pumps)
Ref
No.
New part
Number
Old Part
Number
Description
QTY
1
500100
01-172-406
Cap, cylinder
1
2*
500101
01-172-404
Gasket
2
3
500103
01-178-866
Spring
1
4
500102
01-172-407
Air cylinder
1
5
500138
01-162-729
Plate, air
exhaust valve
1
6
500137
01-189-210
Piston, air
1
7
500140
01-181-485
Spacer, valve
plate
3
8*
500144
01-108-358
O-Ring
3
9*
500141
01-108-357
O-Ring
1
10
500139
01-181-487
Plate, air intake
valve
1
11
500143
01-220-884-1
Copper gasket
3
12
500142
01-220-884
Screw, socket
head cap;
6-32 X 1"
3
13
500104
01-157-872
Washer, valve
1
14
500105
01-178-780
Spring
1
15
500106
01-215-947
Shaft, piston
1
16
500113
01-180-166
Cotter Pin
Dia. 2 X 16
1
17
500112
01-178-923
Pin, headed,
straight
1
18*
500110
01-172-585
Packing, v-
block (NBR)
1
19
500109
01-215-946
Base, air motor
1
20
500134
01-990-005
Fitting, air line
1
21
500133
01-990-001
Needle valve
assembly
1
22
500108
01-104-582
Screw M5x10
1
23
500107
01-104-029
Lug, grounding
1
24
500111
01-178-490
Muffler
1
25
700055
01-220-168
Air valve & piston
assembly
1
*Supplied in the repair kit 01-214-584 (New P/N 601005). See the kit in section 5.0.

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4.2 Parts drawing for Fluid Section of Carbon Steel Drum Pump (IP01)

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4.1 Parts list for Fluid Section of Carbon Steel Drum Pump (IP01)
Ref
No.
New Part
Number
Old Part
Number
Description
QTY
1
500115
01-104-541
Nut, lock, M8
3
2
500117
01-177-152
Nut, packing
1
3*
500118
01-178-543CS
Gland, female
1
4
500116
01-177-171
Tie rod
3
5*
500119
01-177-164
V-packing
(Polyethylene)
3
6*
500120
01-172-385CS
Gland, male
1
7
500122
01-101-281
Fitting, grease
1
8
500121
01-178-542
Housing, outlet
1
9
500124
01-104-537
O-Ring (PTFE)
2
10
500146
01-217-359-B
Cap, bung
adapter
1
11
500147
01-217-359-D
O-Ring
1
12
500145
01-217-359-A
Adapter, bung
1
13
500053
01-217-359-C
Gasket
1
14
500128
01-172-416
Cylinder, 55
Gallon
1
15
500114
01-177-156
O-Ring (Viton)
1
16
500123
01-217-189
Rod,
displacement
1
17
500125
01-105-775
Nut, hex
2
18
500126
01-177-150
Rod,
connecting
1
19
500129
01-177-168
Housing, valve,
piston
1
20
500130
01-177-155
Valve, piston
1
21
500131
01-172-393CS
Washer
(C/Steel)
1
22*
500132
01-177-159
Cup, piston
(Polyethylene)
1
23
500127
01-177-151
Piston, pump
1
24
500193
OP601-1-4X
Snap Ring
1
25
500192
OP601-1-3X
E-clip
1
26
500269
02-101-917
S/Steel Ball
1
27
500196
01-990-006X
Foot Valve
1
28
700015
01-217-359
Bung adapter
Assembly
1
N/A
810101
01-226-941
IP01 Pump
1
* Supplied in the repair kit 01-215-964 (new P/N 601006). See the kit in section 5.0.